Visor for a vehicle

ABSTRACT

A visor for a vehicle is disclosed that is configured for movement between a stowed and one or more use positions and between a front position and a side position. The visor may include consumer devices such as mirrors, illumination devices, holders, instruments, etc. and may have an exterior surface that is textured, colored or configured to match or compliment and interior trim scheme of the vehicle. The visor has a body made from a material configured to be deform or yield during events such as deployment of an overhead frontal air bag system. A bracket assembly for positioning the visor during normal conditions is provided with the body of the visor and configured for attachment of the visor to a structure of the vehicle.

CROSS REFERENCE TO RELATED APPLICATIONS

The present Application claims the benefit of priority, as available under 35 U.S.C. § 119(e)(1) to U.S. Provisional Patent Application No. 60/485,549 titled “Visor for a Vehicle” filed on Jul. 8, 2003 (which is incorporated by reference in its entirety).

FIELD

The present invention relates to a visor for use in a vehicle. The present invention relates more particularly to a visor for use with an overhead frontal air bag deployment system for a vehicle. The present invention relates more particularly to a visor that is configured to deform or yield during an event such as deployment of an overhead frontal air bag system in a vehicle.

BACKGROUND

Visors for use in vehicles are generally known and are typically configured for pivoting about a generally vertical axis for positioning along a windshield or side window of a vehicle, and are also typically configured for pivoting about a horizontal axis between a stowed position (e.g. along a headliner) and one or more use positions to shield an occupant of the vehicle from sunlight, etc.

In such known visors for vehicles, the visor typically includes a body portion made of plastic or the like, and a rod member positioned within the visor body so that the visor body may pivot or slide relative to the rod member. Such known visors typically result in a relatively rigid construction. The rod member is usually connected in a pivoting manner to a bracket that is fixed to an overhead frontal structure of the vehicle such as a cross bow, header, pillar or roof panel.

Recent developments in vehicle safety systems for occupant protection include the positioning of air bag devices in an overhead frontal location within the vehicle for deployment (e.g. along a windshield) to absorb impact energy from an occupant during events such as collisions and other impact to the vehicle. However, such known visors are typically provided in a location that may interfere with the deployment path for such overhead frontal air bag systems. The known visors have a further disadvantage in that the generally rigid construction of such known visors may interfere with the deployment of such overhead frontal air bag systems.

Accordingly, it would be advantageous to provide a visor for a vehicle that provides (during “normal” conditions) a full range of movement between a stowed position and one or more use positions, and between a front position along a windshield and a side position along a side window for use by an occupant in providing shade or shielding sunlight. It would also be advantageous to provide a visor for a vehicle that is constructed with devices for use by an occupant, such as mirrors, lights, holders, electronics, instruments, etc. It would be further advantageous to provide a visor for a vehicle that is compatible for use with overhead frontal air bag deployment systems. It would be further advantageous to provide a visor for a vehicle that is configured to be repositionable during events such as deployment of an overhead frontal air bag system. It would be further advantageous to provide a visor for a vehicle that is made from a material that is configured to deflect, deform or otherwise “yield” during events such as deployment of an overhead frontal air bag system, regardless of the preexisting position of the visor.

Accordingly, it would be advantageous to provide a visor for a vehicle having any one or more of these or other advantageous features.

SUMMARY

The present invention relates to a visor for a vehicle that is configured for movement between a stowed and one or more use positions and between a front position and a side position. The visor may include consumer devices such as mirrors, illumination devices, holders, electronics, instruments, etc. and may have an exterior surface (e.g. “skin” etc.) that is textured, colored or configured to compliment or coordinate with an interior trim scheme of the vehicle. The visor has a body portion made from a material having sufficient rigidity and durability to withstand normal usage demands, yet has characteristics that permit the visor body to “yield” during events such as deployment of an overhead frontal air bag system. A bracket for positioning the visor during “normal” conditions is provided with the body of the visor and configured for attachment of the visor to a structure of the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a visor for a vehicle according to one embodiment.

FIG. 2 is a schematic representation of a visor for a vehicle according to another embodiment.

DETAILED DESCRIPTION

The visor for a vehicle is shown and described for use in a frontal location of a vehicle and configured for use with an overhead frontal air bag system. However, the description of the various embodiments of the visor for a vehicle are equally applicable for use in other locations of a vehicle and for use with air bag systems in other locations of a vehicle, or for use with other systems designed for rapid deployment where it is desirable to avoid interference with a visor.

Referring to FIGS. 1 and 2, a visor for a vehicle is shown according to one embodiment. The visor 10 includes a body portion 20 (e.g. core, etc.), a bracket assembly 40 (shown schematically in FIG. 1), or 140 (shown schematically in FIG. 2), and is shown with one or more consumer devices 14 (such as, for example, as a mirror, a light, buttons for electronics, etc.). The visor 10 is shown located at a frontal overhead location (e.g. adjacent a windshield 12 and along a headliner 15) and is configured for use with occupant protection systems such as an overhead frontal air bag system 13 shown for example as located generally between headliner 15 and a roof panel 17 (such as shown and described in U.S. Provisional Patent Application No. 60/387,615 titled “Overhead Front Air Bag Deployment System” filed Jun. 11, 2002, the disclosure of which is incorporated be reference herein in its entirety).

The body portion 20 of the visor may be located within the vehicle interior at any suitable location and movable to any suitable position to provide sun shielding to an occupant. During deployment of such overhead frontal airbag systems, it would be desirable to provide a visor that will “deflect,” “yield” or otherwise be repositioned, regardless of the visor's preexisting position, in a manner intended to avoid interfering with the deployment of an air bag.

The body portion 20 of visor 10 is formed from a material that has sufficient rigidity and durability to withstand normal usage and to serve as a “conventional” visor during “normal” conditions (e.g. where deployment of such an air bag system is not required). The material is intended to have characteristics that permit the body portion of the visor to “yield” (e.g. deform, deflect, fold, break, tear, collapse, etc.) under predetermined forces that are typically associated with deployment of an overhead frontal air bag system. According to a preferred embodiment, the material is a generally “rigid” foam and may be formed in any suitable process such as molding, expansion, extrusion, etc. The material of the body portion is provided with an external surface 18 (e.g. “skin”) that may be “finished” (e.g. textured, colored, etc.) to compliment an interior trim scheme within the vehicle (e.g. having an appearance representative of vinyl, cloth, leather, etc.).

According to an alternative embodiment the material of the body portion may be made of a laminated foam construction, or of any other suitable material, such as, for example, cardboard, paper materials, etc. According to another alternative embodiment, the material of the body portion may be provided with certain “weakened” locations, such as by providing scoring, perforations, etc. that are intended to enhance the capability of the body portion to yield, or to precipitate a location at which the body portion will yield during deployment of an overhead frontal airbag system.

Various consumer devices 14 may be included within body portion 20 for the use and comfort of the occupants of the vehicle. Such consumer devices may include, but are not limited to, mirrors, brackets, lamps, lights or other illumination devices, electronics or instrumentation (e.g. compasses, transmitters, receivers, “buttons” for controlling other devices, etc.). The mirror may be provided with a pivot member (shown as pivot axle 16) that is intended to permit the mirror to be pivoted within the body portion for enhanced convenience of the occupants of the vehicle. The light may be provided with directional capability (e.g. pivot, swivel, focal adjustment, etc.) to enhance the utility of the light to the occupants of the vehicle.

The consumer devices 14 may be attached to the body portion 20, or may be integrally formed with the body portion (e.g. insert molded, clamped, snap-fit, etc.). Suitable wiring or other circuitry (not shown) for transmitting power or signals to or from the consumer devices may also be formed within or routed through passages within the body portion to the bracket assembly to couple with the vehicle's power or instrumentation systems. According to a preferred embodiment, the consumer devices 14 are located near one or both ends of the body portion 20. The location of the consumer devices near the ends of the visor body is intended to avoid placement of such devices within a deployment “zone” or “path” (shown generally as area 22 in FIG. 2) provided generally within a midsection of body portion 20, within which the body portion would be expected to “yield” during deployment of an overhead frontal air bag system. Placement of such consumer devices outside of zone 22 is intended to prevent such consumer devices from interfering with the ability of the body portion to yield upon demand. According to an alternative embodiment, the consumer devices may be provided in any location on the visor and configured to yield with the body portion of the visor in a manner that does not interfere with the ability of the body portion to yield upon deployment of the air bag.

Referring further to FIG. 1, a bracket assembly 40 for the visor 10 is shown according to one preferred embodiment. The bracket assembly 40 is shown schematically to include an extension or projection (shown as a web 42) that extends partially into the body portion 20 of the visor 10. Web 42 may be formed of any suitable material such as plastic in a molding operation and is configured to provide a mounting interface between the body portion and an attachment member (shown schematically as an elbow 50). The web 42 may be formed as a generally “flat” or solid member or may have a “tubular” construction. According to a preferred embodiment, the web 42 may be integrally formed within the body portion 20 (e.g. by insert molding, foaming the material about the web, snap-fit connectors, “clamping” the projection between portions of the body such as in a “clamshell” configuration or the like) or the web 40 may be secured to the body portion 20 by adhesion, fasteners, compression fit or other suitable connection. According to an alternative embodiment, the projection may be configured in a “clamshell” arrangement to “grip” the body portion therebetween.

The web 42 includes a base region with a collar 44 extending outwardly therefrom. The collar 44 includes a generally hollow interior configured to receive an axle member 52 of the elbow 50. The hollow interior of the collar 44 may have one or more “flats” or “detents” configured to resiliently engage the axle member 52 of elbow 50 (e.g. by a spring, etc.—not shown) that permits positioning of the body portion in one or more predetermined locations (e.g. stowed, use, forward use, etc.) by rotating the body portion of the visor (and hence the collar) relative to the axle member. According to an alternative embodiment, the orientation of the collar and axle member may be reversed so that the collar extends from the elbow and the axle member extends from the web.

The elbow 50 is configured for attachment to a structure of the vehicle (e.g. pillar, cross beam, roof panel, air bag mounting bracket, etc.) in a pivoting or swiveling manner and may be secured thereto in a conventional manner (e.g. by fasteners, resilient clips, Z-axis clips or the like, etc.—not shown). The axle member 52 extends from the elbow 50 for engagement with, and is shown retained within, the collar 44 (e.g. by spring clip or the like). During an event that results in deployment of an overhead frontal air bag system, the bracket assembly 40 is intended to remain coupled to the structure of the vehicle, while the body portion 20 of the visor 10 yields or otherwise deforms relative to the bracket assembly 40. According to an alternative embodiment, the bracket assembly may be configured for deformation to permit the body portion of the visor to “deflect” or otherwise reposition away from the path of the air bag during deployment.

Referring to FIG. 2, a bracket assembly 140 for a visor 10 is shown according to another preferred embodiment. The bracket assembly 140 is similar to bracket assembly 40 as previously described, but provides a clip member 142 secured to body portion 20 and configured to rotate about axle member 52. The clip member 142 may be integrally formed within body portion, attached or adhered to the body portion, or may “clamp” the material of the body portion between opposite sides of the clip member.

According to any preferred embodiment, the visor for a vehicle is intended for use with a wide variety of devices such as mirrors, holders, illumination devices, instruments, etc. and to provide a full range of motion such as are typically available with conventionally known visors. The material for the body portion of the visor for a vehicle is intended to provide sufficient durability and rigidity for all typical uses during “normal” conditions, but has material characteristics that permit the body of the visor to “yield” (e.g. collapse, fold, tear, breakaway or otherwise be repositioned) under the typical forces associated with deployment of an overhead frontal air bag, without interfering with the deployment of the overhead frontal air bag. The body portion of the visor may remain attached to the bracket assembly during or following deployment of the air bag, or the body portion may be configured to detach or otherwise become separated from the bracket assembly during or following deployment of the air bag.

It is important to note that the construction and arrangement of the elements of the various embodiments of the visor for a vehicle provided herein is illustrative only. Although only a few exemplary embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible in these embodiments (such as variations in bracket configurations, methods of attachment of the bracket to the structure of the vehicle, surface textures or treatments, devices provided in the visor body for use by an occupant, materials of construction for the body portion, location of the visor, mounting arrangements for the bracket assembly, use of colors, combinations of shapes, etc.) without materially departing from the novel teachings and advantages of the inventions. Further, the visor for a vehicle may be used in any type of vehicle such as trucks, recreational vehicles, minivans, sport utility vehicles, passenger automobiles, etc. and at any suitable location within the vehicle. Accordingly, all such modifications are intended to be within the scope of the invention as defined in the appended claims.

The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the inventions as expressed in the appended claims. 

1. A visor for a vehicle for use with an overhead airbag system, the visor comprising: a bracket configured for attachment to the vehicle; a body portion coupled to the bracket and configured for movement between at least one of a stowed position and a use position, and a front position and a side position; the body portion comprising a deformable material configured to yield in the event of impact during a deployment of the airbag system.
 2. The visor of claim 1 wherein the deformable material comprises a foam material.
 3. The visor of claim 2 wherein the foam material comprises a laminated foam material.
 4. The visor of claim 1 wherein the body portion further comprises at least one consumer device.
 5. The visor of claim 4 wherein the consumer device includes at least one of a mirror, an illumination device, an electronic component, an instrument, and a holder.
 6. The visor of claim 4 wherein the at least one consumer device is located proximate at least one end of the body portion
 7. The visor of claim 4 wherein the consumer devices are insert molded within the body portion.
 8. The visor of claim 4 further comprising wires routed through the body portion and the bracket to engage the at least one consumer device.
 9. The visor of claim 1 wherein the visor is configured to be installed beneath the overhead air bag system.
 10. The visor of claim 1 wherein the bracket comprises a projection that extending at least partially within the body portion.
 11. The visor of claim 10 wherein the projection comprises a web.
 12. The visor of claim 10 wherein the projection is insert molded within the body portion.
 13. A visor assembly for a vehicle comprising a bracket configured to mount a body portion of the visor assembly to an interior of the vehicle, the body portion comprising a foam material configured to yield in the event that the body portion is positioned within a deployment path of an airbag system.
 14. The visor of claim 13 wherein the bracket is formed from a material comprising a plastic material.
 15. The visor of claim 13 wherein the bracket comprises a projection in a clamshell configuration to capture the material of the body portion therebetween.
 16. The visor of claim 13 wherein the bracket includes a projection that extends within the body portion and is adhered to the material of the body portion.
 17. The visor of claim 13 wherein the bracket includes a projection that is clamped within the body portion.
 18. The visor of claim 13 wherein the bracket includes a projection that is insert molded within the body portion.
 19. The visor of claim 13 wherein the bracket includes a projection that is molded with the body portion.
 20. The visor of claim 13 wherein the body portion includes a mirror that is rotatable within the body portion.
 21. The visor of claim 13 further comprising a light device that is repositionable.
 22. A method of making a visor for use in vehicles having an overhead airbag system, comprising: providing a bracket having a first portion configured for attachment to a visor body and a second portion configured for attachment to an interior of the vehicle; forming the visor body from a material having a sufficient rigidity to maintain a first shape for use in shielding an occupant of the vehicle and a sufficient flexibility to deform into a second position in the event of impact with the overhead airbag system to minimize interference with deployment of the airbag system and to minimize damage to the bracket.
 23. The visor of claim 22 wherein the material comprises a foam material.
 24. The visor of claim 23 wherein the foam material comprises a laminated foam material.
 25. The visor of claim 22 wherein the visor body further comprises at least one consumer device.
 26. The visor of claim 25 wherein the consumer device includes at least one of a mirror, an illumination device, an electronic component, an instrument, and a holder.
 27. The visor of claim 25 wherein the at least one consumer device is located proximate at least one end of the visor body.
 28. The visor of claim 25 wherein the consumer devices are insert molded within the body portion. 